Installation Guidelines For Audi-VW 6-Speed DSG .

Installation Guidelines For Audi-VW 6-Speed DSG Transmission Fluid Filter Change Kit(02E - Double Clutch Transmissions)! CAUTION !Performing work on your automobile without having proper knowledge, mechanical abilityor the proper tools and safety equipment, can cause severe injury, death or automobile mechanical problems!BLAUfergnugen! Inc. recommends you have an A.S.E. Certified Audi Vw Technician install your parts to ensure your safety.ALWAYS WEAR SAFETY GLASSES AND OTHER SAFETY ITEMS WHEN PERFORMING THE FOLLOWING WORK !Always read the factory service manual safety instructions and guideline before installing this kit.Check the factory manual and always verify the automatic transmission fluid supplied in this kit is recommended for your specificmodel and year vehicle. Failing to verify can result in transmission failure.NOTE: It is best to use a drain pan that has measuring capacities, you will then have an accurate idea of the amount of new fluid to put back into thetransmission.NOTE: Many of the steps below are to be performed on an approved automotive lift. Warning: Use safety precautions. People should never be underthe car or in front of the wheels when performing this operation! Serious injury or death could result!NOTE: When performing the transmission fluid and filter service, the vehicle should be completely level on an approved automotive lift or jack stands.NOTE: When performing transmission maintenance, cleanliness is of great importance. Always use lint free rags, confirm all transmission parts areclean, and cover transmission components when removed from transmission.PLEASE READ: The 02E 6 speed DSG transmissions are equipped in several Audi VW models. Depending on the model and year of your vehiclethere will be slight differences in the battery box area. An example of this is some cars where not equipped with a plastic battery box cover but rathercame with a soft black insulation cover. The instructional image references still apply.1. With the the engine bay accessible remove the battery cover by pushing in the lock tab and pull up.(Image 1)2. Remove the front side of the battery box. Push in the two tabs on the front while pulling up. (Image 2)(Note: Some vehicles are equipped with an surrounding insulation cover not a plastic battery box. If your vehicle is equipped with aninsulation cover, remove the insulation cover with the battery in step 5.)3. Disconnect the battery power cables. Both the positive and negative cable clamps are 10mm. (Image 3)IMAGE 2IMAGE 1IMAGE 3Page 1Copyright BLAUfergnügen ! Inc. 2016Form # INS211

4. Remove the battery hold down bracket. This is held in place by a 13mm bolt and located at the passengerside base of the battery between the engine cover and battery. (Image 4 and 5)IMAGE 4IMAGE 55. Remove the battery along with the battery insulation. (Image 6)6. Remove the three 10mm bolts holding the battery tray frame in place. (Image 7 and 8)IMAGE 7IMAGE 6IMAGE 8Page 2Copyright BLAUfergnügen ! Inc. 2016Form # INS211

7. Pull up the battery tray frame to allow access to the rear side of the battery box. With the rear side of thebattery box exposed un-clip the rear side of the battery box. (Image 9 and 10)IMAGE 10IMAGE 98. Remove the battery tray frame by first pulling the rear of the battery tray frame up and then back to the firewall at an upward angle. The battery tray frame may have to be slightly twisted and or maneuvered in such away to not tangle the battery and fuse box wires. (Image 11)9. Elevate the vehicle on an approved automotive lift or jack stands using the factory lift points to a levelposition. (See the factory owners manual for approved factory vehicle lift points.)10. Remove the lower engine protective splash pan. The small sized splash pan is held in place by several t25 torx screws. If it is a full size splash pan there are both t-25 and t-30 torx holding the splash pan in place.(Image 12)IMAGE 11IMAGE 1211. Remove the 14mm DSG transmission drainplug along with the crush washer. Allow the DSGfluid to drain from the transmission. During thisstep not all DSG transmission fluid will drain fromthe transmission. Roughly only 1.5 – 2 Liters ofDSG fluid will drain. (Image 13, 14, and 15)IMAGE 13Page 3Copyright BLAUfergnügen ! Inc. 2016Form # INS211

IMAGE 14IMAGE 1512. Drain the remaining DSG transmission fluid by removing the transmission fluid level insert.This is a 8mm six point allen recessed up inside the drain plug port. (Image 16, 17, 18, and 19)IMAGE 16IMAGE 17IMAGE 18IMAGE 19Page 4Copyright BLAUfergnügen ! Inc. 2016Form # INS211

13. Once you have confirmed all the old DSG transmission fluid has drained from the transmission reinstallthe transmission fluid level insert and tighten to 2 ft. lbs.14. Install filling tool adapter VAS 6262BL hand tight. Secure the filling hose to adapter VAS 6262 and directthe other end of the hose up in front of the transmission to the top side of the engine bay.(Image 20)15. Locate the DSG transmission filter housing at the top of the transmission. This is a black plastic housing.Using a 24mm socket loosen and remove the housing. You may want to consider placing several rags aroundthe filter area to absorb any spillage. (Image 21)IMAGE 20IMAGE 2116. Remove the DSG transmission filter by firmlypulling upward. You may want to grasp the filterusing a large clean rag as this can minimize anysplash that happens when the filter pops upward.(Image 22)17. Install the new DSG transmission filter in thesame orientation as the old one. Confirm the filtero-ring area has popped onto the transmission.(Image 23)18. Remove and replace the sealing o-ring on theDSG transmission filter housing. It is best to mildlylubricate the new o-ring with some clean DSG fluidto minimize the chance of the o-ring scarring andnot achieving a proper seal. (Image 24)IMAGE 22IMAGE 23IMAGE 24Page 5Copyright BLAUfergnügen ! Inc. 2016Form # INS211

19. Reinstall the transmission filter housing. Confirm that you do not cross thread the housing while tightening.Tighten the DSG filter housing to 15 ft. lbs. Do not over torque the DSG transmission filter housing as this cancause difficulty during future DSG transmission service. (Image 25 and 26)IMAGE 25IMAGE 2620. Reinstall the battery tray and tighten the three 10mm bolts to 5 ft. lbs. (Image 27 and 28)IMAGE 27IMAGE 2821. Reinstall the rear side of the battery box cover. Confirm all the tabs are popped into place and the batterycable on the back side is routed properly. (Image 29)(Note: Some vehicles are equipped with just a surrounding insulationcover not a plastic battery box. If your vehicle is equipped with an insulation cover proceed to step 22.)IMAGE 29Page 6Copyright BLAUfergnügen ! Inc. 2016Form # INS211

22. Reinstall the battery in the proper direction of the power and ground cables along with the batteryinsulation. (Image 30)23. Reinstall the 13mm battery hold down bolt and bracket located on the passenger side of the battery. This isbetween the engine cover and the battery. (Image 31 and 32)24. Reinstall the battery power cables and tighten 10mm nuts/bolts to 4 ft. lbs. (Image 33)IMAGE 30IMAGE 31IMAGE 32IMAGE 3325. Reinstall the front side of the plastic battery cover. Confirm the front lock tabs and the side alignmentchannels are installed correctly. (Image 34 and 35)(Note: Some vehicles are not equipped with a plastic cover. Somevehicles came with a surrounding insulation cover If your vehicle is equipped with an insulation cover proceed to step 27.)IMAGE 34Page 7IMAGE 35Copyright BLAUfergnügen ! Inc. 2016Form # INS211

26. Install the top battery cover. Confirm the two tabs on the rear of the cover are installed and allow the frontto snap down. (Image 36)DSG Transmission Fluid Filling Procedure:27. With the filling tool adapter VAS 6262 installed, slide the fill hose on as pictured. (Image 37)IMAGE 36IMAGE 3728. With the fill hose up in front of the transmission,connect the hose to the fluid bottles as described inthe supplied tool and hose kit instructions. Connectthe hose to the DSG fluid bottle as described in thesupplied instructions. (Image 38)29. Allow around 2.5 liters of DSG fluid to flow bygravity into the transmission. As fluid is being fedinto the transmission, with the vehicle elevated, andlevel off the ground, start the vehicle. With thebrakes applied, shift/select through all the gears ofthe transmission while the engine is idling. Allow 5seconds for each gear selection. While the engine isin park and idling, continue to gravity feed the DSGfluid into the transmission. This will allow severalmore liters to flow into the transmission. Allow all 5-6liters to empty and flow into the transmission,remove the fill adapter, and install the drain plug withnew sealing washer. (Image 39 and 40)IMAGE 38(To allow for a quicker flow of DSG fluid into the transmission you may use pump tool number J91001 available at blauparts.com.)IMAGE 39Page 8IMAGE 40Copyright BLAUfergnügen ! Inc. 2016Form # INS211

30. As the engine is at idle. Plug the Ross-Tech diagnostic software into the OBD2 port and begin to monitorthe transmission fluid temperature.Using the Ross-Tech,1st Select Control Module (Image 41),2nd 02-Auto Trans Control Module (Image 42),3rd Measuring Blocks – 08 (Image 43),4th Group 019 (Image 44).Display group 019 in field 1 will allow for an accurate DSG fluid temperature reading.IMAGE 41IMAGE 42IMAGE 43IMAGE 4431. With the vehicle level, bring the transmission fluid temperature to warm between 35 C - 45C (95 F –113 F). At this temperature range, a little transmission fluid should begin to flow out from the fill port levelinsert. When this happens, the proper DSG fluid level has been achieved. Note: Do not allow thetransmission temperature to exceed 45C (113 F).32. Reinstall the 14mm allen drain plug with new sealing crush washer and torque to 22 ft lbs. 22 ft lbs allowsfor an adequate compression and sealing of the drain plug crush washer.33. Once the proper transmission fluid level has been attained, turn the engine off and exit the Ross-Techdiagnostic software and disconnect the OBD2 plug port.NOTE: If no fluid drips from the fill port, proper level has not been achieved. Reinstall the 5mm allen drainplug, turn off the engine, and allow the transmission to cool to below 30 C (86 F). Repeat the transmissionfluid level process per the above recommendations. (Steps 27-33)34. Re-install the lower engine splash pan with T-25 torx.35. Remove the vehicle from the approved automotive lift or jack stands using factory lift points andprocedures.Page 9Copyright BLAUfergnügen ! Inc. 2016Form # INS211

29. Allow around 2.5 liters of DSG fluid to flow by gravity into the transmission. As fluid is being fed into the transmission, with the vehicle elevated, and level off the ground, start the vehicle. With the brakes applied, shift/select through all the gears of the transmission while the engine is idling. Allow 5 seconds for each gear selection.